Abstract
The article is the continuation of a cycle of works published in a Special Issue of MDPI entitled “Innovative Technologies and Materials for the Production of Mechanical, Thermal and Corrosion Wear-Resistant Surface Layers and Coatings” related to tests concerning the microstructure and mechanical properties of innovative surface layers made using the Powder Plasma Transferred Arc Welding (PPTAW) method and intended for work surfaces of drilling tools and machinery applied in the extraction industry. A layer subjected to tests was a metal matrix composite, made using powder based on a nickel alloy containing spherical fused tungsten carbide (SFTC) particles, which are fused tungsten carbide (FTC) particles and spherical particles of tungsten-coated synthetic metal–diamond composite (PD-W). The layer was deposited on the substrate of low-alloy structural steel grade AISI 4715. The results showed that the chemical composition of the metallic powder as well as the content of the hard phase constituting the matrix enabled the making of a powder filler material characterised by very good weldability and appropriate melting. It was also found that the structure of the Ni-WC-PD-W layer was complex and that proper claddings (characterised by the uniform distribution of tungsten carbide (WC)) were formed in relation to specific cladding process parameters. In addition, the structure of the composite layer revealed the partial thermal and structural decomposition of tungsten carbide, while the particles of the synthetic metal–diamond composite remained coherent. The deposited surface layer was characterised by favourable resistance to moderate dynamic impact loads with a potential energy of 200 J, yet at the same time, by over 12 times lower metal–mineral abrasive wear resistance than the previously tested surface layer made of cobalt-based composite powder, the matrix of which contained the hard phase composed of TiC particles and synthetic metal–diamond composite. The lower abrasive wear resistance could result from a different mechanism responsible for the hardening of the spherical particles of the hard phase susceptible to separation from the metal matrix, as well as from a different mechanism of tribological wear.
Highlights
IntroductionMost plasma cladding applications involve the use of a powder filler material enabling the obtainment of deposited layers characterised by various chemical compositions, structure and properties [1,2]
4.5%. mixture components was made in the contrast of back-scattered electrons (BSE); the bright particles the tungsten carbide particles, whereas the darker particles are the nickel alloy
The obtained layer was characterised by the classical composite structure and the The research-related tests aimed to assess the metallographic structure as well as to uniform distribution of reinforcement composed of primary tungsten carbides (WCidentify the metal–mineral abrasive wear resistance and the impact resistance of the innoW2 C) and the particles of synthetic metal–diamond sinter in the matrix composed of vative composite surface layer obtained using the Powder Plasma Transferred Arc Welding the γ-Ni solid solution and the γ-Ni/Ni3 B eutectic phase
Summary
Most plasma cladding applications involve the use of a powder filler material enabling the obtainment of deposited layers characterised by various chemical compositions, structure and properties [1,2]. In deposited layers that have the structure of composite materials (used to improve the abrasive wear resistance of drilling tools or machinery), the matrix is usually composed of cobalt, nickel or iron-based alloys containing particles of high-melting phases, e.g., carbides of transition metals found in groups IVB–VIB of the periodic table [3,4]. High melting points and high thermodynamic stability constitute the primary and very desirable features of the aforesaid carbides [5]. The combination of hard carbide phases with the relatively plastic metal matrix significantly improves the functional properties of surface layers exposed to various types of abrasion
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